Method and apparatus for producing novelty yarn



a.. MTV 1956 H, HoF-MANN W METHOD AND APPARATUS FOR PRODUCING NOVELTYYARN Filed Dec. 24, 1952 2 SheebS-Sheei l METHOD AND APPARATUS FORPRODUCING NOVELTY YARN .INI/ENOR..

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-i-'L HOFMAN N Filed Dec. 24, 1952 United States Patent() METHOD ANDAPPARATUS FOR PRODUCING NOVELTY YARN Hugo Hofmann, Eliznbethton, Tenn.,assigner to leaunit Mills, Incorporated, New York, N. Y., a corporationof New York Application December' 24, 1952, Serial No. 327,875

11 Claims. (ci. ls-s) The present invention is concerned with a methodand apparatus for the production of novelty yarns of syntheticfilamentary material having improved strength and softness.

Silk thread which is obtained from imperfect or freak cocoons, or fromcocoons of wild or uncultivated silk worms has an imperfect texture andis characterized by having thickened portions or nubs spaced atirregular intervals. It was early discovered that such yarn could beutilized in the production of fabric having a pleasing appearance, sincethe nubs occurred at irregular intervals and therefore did not tend toproduce a pattern effect.

Producers of synthetic tilamentary material have striven to simulate theimperfections occurring in such silk, and to produce an articial yarnwhich would be acceptable as a substitute for the product produced bythe silk worm. While the patent literature is replete with methods andapparatus for making an acceptable nubby yarn, much of this art fallsshort of its goal due to the difficulty of obtaining nubs on articialfilaments in a completely irregular and indeterminable fashion. One suchfunnel spinning method which has proven successful isset forth in U. S.Patent 2,251,247, assigned to the present assignee. According to theprocess of this patent, a synthetic iilamentary bundle is extruded in anormal manner, but instead of being taken up from the funnel outlet asis normal, the iilamentary bundle is caused to impinge upon a tiltedglass plate disposed beneath the funnel, causing the partiallycoagulated filaments to pile up and in so doing nubs are produced atirregular intervals. The slubby filaments are taken up and combined witha normally spun filament bundle from a spinning funnel disposed adjacentthereto; This process is carried out with the conventional singlespinning funnels in their normal spinning positions.

In the production of synthetic filaments by the funnel spinning process,it has been discovered that smaller spinning funnels are capable ofrendering a more uniform thread which may be doubled with another threadbundle similarly produced. By doubling filament bundles so produced tomake a required denier, it has been found that the yarn is rendered moreuniform, not only owing to the doubling, but also because the individualmultiple threads have a more uniform structure as regards physicalproperties and dyeing characteristics.

p It has been further proven that a thread comprising two or morelamentary bundles doubled or tripled possesses a special structure, dueto the fact that the filaments of the multiple bundle, during thespinning process, stick to one another 'and impart to the filaments andfabric made therefrom an entirely different characteristic feel.

While the method and apparatus as set forth in Patent 2,251,247previously referred to `has proven fairly satisfactory for theproduction of a higher denier composite yarn, the apparatus employed isof the conventional type inthat the individual filament bundles are spunfrom 2,730,757 Patented Jan. 17, 1956 ICC tunnels of standardconstruction corresponding in number to the winding up points.

The principal object, therefore, of the present invention is to producesynthetic filaments having a novel slubby effect at indeterminableintervals from a multiple of small spinning funnels, each of which isintended to produce only a thin component filament bundle. As desired,two or more such component filament bundles, at least one of which isslubbed at irregular intervals by means of a novel funnel arrangement,are brought together to form a composite slubby filament bundle.

It is a further object of the present invention to produce a compositefilament yarn having a novel slubbed effect and which is characterizedby having increased strength and softness.

A further object is to provide a method and apparatus for producing anovel slubby yarn of artificial origin wherein the maximum utilizationof machine space and productivity is obtained without requiring anincrease in the number of machine operators.

A stiil further object resides in the provision of a method andapparatus whereby the frequency and size of the slubs produced can bevaried to a degree at the will of the operator but without producing apattern effect.

Further objects and advantages over the prior art discussed will beapparent from the description of the irivention which follows.

Referring to the drawings in which:

Fig. l is a fragmentary plan View of one of the multiple spinningfunnels according to the present invention along with its respectiveuniting and guide means and the collecting reel therefor.

Fig. 2 is a side elevation of Fig. l showing one form of the apparatusaccording to the present invention.

Fig. 3 shows an alternative filament slubbing receptacle which may beused in place of the tilted tiat `surface shown in Fig. 2.

Fi g. 4 is a longitudinal sectional view through a multiple spinningfunnel constructed in accordance withthe present invention.

Fig. 5 is a horizontal sectional view taken along the line S--S of Fig.4 and looking up toward the spinnerette.

Fig. 6 shows a spinnerette constructed in accordance with the presentinvention with the extrusion holes being magnified to more clearlyindicate difference in hole size.

in the drawings in which like reference numerals indicate like parts, 10generally designates a spinning head constructed in accordance with thepresent invention. The head 10 comprises a head piece 12 which enclosesa multiple spinnerette 14 (Fig. 6). Head piecel12 is provided with adepending iiange 16, into whichthe upper end of a glass cylinder 18 iscemented.

A spinning solution manifold 20 (Fig. 2), delivers spinning solution tothe space 11 above spinnerette 14 through the lead tube 22 as iscustomary in the funnel spinning process. Glass cylinder 18 is cementedto the head piece 1i as shown at 24. A bottom funnel piece 26 iscemented to cylinder 13 at the point 28. The bottom funnel piece 26 isprovided with an annular coagulating liquid receiving and distributingpassage 30 at its lower end. t

A coagulating liuid inlet opening 34 leading to the passage 30 serves tosupply the spinning head 1U with a constant ow of coagulating iiuidwhich is distributed from the passage 30 through openings`31 and iiowsupwardly within the area 27 of funnel 18 until it overflows into themultiple spinning funnels which will now be more fully described.

Spinning funnels 36 and 38 are comprised of tapered, tubular memberswhich are held in position by means of the.. cement 3.3., which isappliedbelow the bottomy funnel piece 26.

The upper ends 36 and 38 of funnels 36 and 3S, which extend within thecylinder 18, are flattened on one side and abut each other as shown inFig. 5. The upper ends of funnels 36' and 38 are open andfterminate justbelow the surface of spinnerette 14 in position to receive the filamentsin separate bundles according to denier as they issue from thespinnerette.

Attached to the lower. free ends of each of the funnels t'ivand. 38v arethe flexible coupling members rif and 42.

-Suitable clamps 44 and 46 hold these members in liuid tight engagementwith the funnels. The coupling members. in. turn hold the funnel nipples48 and 50 by means of clamps 45 and 47. It will bev noted that nipple 50is longer than nipple 48 and that the nipple opening 49 is lessrestricted than is the nipple opening Sl. The purpose of thisarrangement will be more fully explained subsequently. It will befurther observed that this arrangement permits the `funnel nipples to beremoved and replaced withonly a momentary interruption in the manufacturing process.

Referring to Figures l and 2, the improved novel yarn of the presentinvention is produced as follows. Spinning solution, which, forillustrative purposes, will be described as being cellulosiccuprammonium, is delivered under suitable pressure from the manifold 26through `lead-in tube 22 to the head space 11 above the spinnerette 1.4A(Fig. 4).. Spinnerette 14 has two sets of orifices therein, with oneside13 having orifices of larger diameter t than the other side 15 (Fig. 6)so that the filaments issuing through holes 13 will be of larger denier.As the filamentsV issue from the spinnerette, coagulating liquid fromthe. manifold is delivered to the opening 34 by means of thetube54 andis distributed by means of the passage 30 and rises around the upperfunnel sections 36 and 3.8: until it overflows the top thereof. Thepressure and volume.. flow of this liquid in large measure controls theSpeed of-extrusion of the filaments in their passage down the funnels.

The coagulating duid is moved through the spinning funnels 3.6 and 38 bymeans of a siphoning action which isa fairly. standard techniqueemployed in the funnel spinning art. However, particular advantage ismade of this siphoning action in the present invention to achievetheobiects thereof. Funnel 38 being longer than funnel 36, and having alarger nipple opening causes more coagulating fluid to be siphonedthrough this funnel to handle the larger denier filaments. beingextruded in this funnel. Alsothe increased flow is necessary in order todeposit the larger denier filaments beneath nipple 50 in a manner to be.hereinafter described.

It. shouldy be emphasized that the same coagulating Huid flows throughboth funnels, so that the larger denier filaments issuing from funnel 38are less coagulated than arefztghejlaments from. funnel 36, since, thecomposition ofthe liquid is adjusted-for the smallerdenier filaments.

The opening 4 9 of nipple 50 is in the neighborhood of 5 mm. and nippleopening 51 may be conveniently 4 Y mm. These openings can be varied inproportion to the denier of thefilaments and theflow of coagulatingliquid, but must be kept to a sizeso that air does not pass upwardlyaround the liquid issuing therefrom and interrupt orinterfere with thesiphoning action necessary for a constant flow of coagulating fluid anda uniform fiber.

The abutting surfaces of the funnels 36 and 38 terminatesadjacent themedial portion of the spinnerette 14 so thatthelarge denier filaments56. issuing from holes 13 aredirected'into funnel 38 and the smallerdenier laments 5,8 to funnel36 i The two filament bundles are moved downtheir respective funnels. at a rate` determined by the flowV ofcoagulating liquid. Due to funnel 36 being of shorter length,filamentsSS are discharged before. filaments 56. Thecoagulating liquid,together with filaments 56. are Vdischarged under slightly greaterpressure than are flinow of liquid plus the increased length of funnelnipple 50, carries the filaments 56 to a flat tilted surface 60 disposedbeneath this funnel. The take up rate is selected for the normally spunfilament and is such as to permit a momentary pile up 57 of filaments56, and since they are in a partially coagulated sticky condition, nubsor slubby portions are formed on the yarn at irregular and completelyindeterminable intervals.

As an alternative to the fiat surface 60, Fig. 3 shows an adjustabledished receptacle 62 which may be placed beneath funnel nipple 50 toreceive the filaments to be slubbed. By the use of this receptacle asomewhat different piling action is achieved in that the pile has atendency to float in the coagulating liquid deposited with the yarnfilaments, so as to render a multiplicity of small slubs rather than aseries of larger more distantly spaced slubs, as in the case of the flatsurface described. Also the slubbing action may be controlled to adegree by varying the distance of the receptacle 62 from the funnel tip50. A distance of 2" has been found quite satisfactory for mostpurposes.

Yarn filament bundle S8 is led under guide rod 62 and both bundles 58and 56 are led over guide red 64 and through the uniting guide member 66where the two partially coagulated filament bundles are united into onecomposite yarntow. The uniting takesplace inthe ab. sence ofregenerating acid, to insure a thorough adhesion ofthe two filamentbundles so that a composite bundle results of-increased strength andwithout any tendency to later separate into their individual componentbundles.

From the uniting guide member 66, the composite bundlev is led throughthe reciprocating guide 68 and thence to the takeup reel 70. Astheyarnis taken up on reel 70, it is subjected to an acid regeneratingbath. The

acid is allowed to dribble on to` the Vsurface of the skein` being takenup, through the medium of a trough-like tongue member 69 secured beneathguide 68. Acid is .delivered to this member by conventional meansnormally employed to deliver coagulating acid to the yarn passingthrough front guide 68.

While the invention has been described in conjunction with the use of acuprammonium cellulose solution, the principles of the invention areapplicable to the funnel spinning of viscose as described in U. S.Patents 2,065,175 and 2,154,893 for example. Further the process andapparatus as described may be used in conneetionV with any of thesynthetic fibers capable of being wet spun from a funnel.

While only two spinning funnels-have been shown for sake of simplicityit is to be. understood that more than two such small funnels may beused with at least one of the funnels being designed to produce a slubbyfilament to be combined with the normally spun filaments. Where morethan two funnels are to be used the spinnerette will b e modified so asto extrudev the desired filament bundle for each type funnel.

In viewof the foregoing description taken in connection withv theaccompanying drawing it is thought the manner and mode of carrying outthe process with the apparatus disclosed will be clear to those skilledin the art to which it relates.

What I claim is:

l. A process for spinning novel filaments of artificialV originV havingimproved strength and softness which comprises the steps of extruding atleast two separate bundles ofvfilamernts from a coagulable cellulosicspinning solution through the medium of a common coagulating bath,

to pile up briefly beneath their funnel outlet and thereafter bringingall of the filament bundles together by means of a filament unitingmeans in the absence of regenerating acid, and collecting the compositefilament bundle so formed While subjecting said composite bundle to theaction of an acid regenerating bath.

2. A process as set forth in claim 1 wherein said cellulosic spinningsolution comprises viscose.

3. A process as set forth in claim 1 wherein said cellulosic spinningsolution comprises cuprammonium.

4. A process as set forth in claim 1 wherein said lilament bundles ofhigher denier are discharged from their respective funnels under greaterpressure than the other filament bundles.

5. A process as set forth in claim 1 wherein said higher denier filamentbundles are caused to pile up brieiiy upon a flat surface prior to beingjoined with the other of said filament bundles.

6. A process as claimed in claim l wherein said higher denier filamentbundles are caused to pile up briefly in a movable dished receptacledisposed beneath said tunnels, said receptacle having therein a bath ofcoagulating liquid.

7. A process for spinning a composite cellulosic filament bundle havingslubs disposed along said fialments at irregular and indeterminableintervals, with the resulting yarn being characterized by improvedstrength and softness, which comprises the steps of extruding at leasttwo separate bundles of filaments from a common spinnerette with a partof said filaments being extruded with a greater denier than the other ofsaid filaments, said filaments being extruded into a common coagulatingbath, separating the extruded filaments into bundles according to denierand discharging said lamentary bundles through separate funnel outlets,said filaments of higher denier being discharged at a greater pressurethan the other of said filaments so as to cause a momentary piling up ofsaid filaments beneath their funnel outlets, thereafter bringing all ofthe filaments together by drawing said filaments through a uniting meansin the absence of regencrating acid, collecting the composite filamentbundle so formed while subjecting said bundle to the action of an acidregenerating bath.

8. Apparatus for spinning novel filaments of artificial origin havingimproved strength and softness comprising means for delivering acellulosic spinning solution at a predetermined pressure, precipitatingapparatus to receive said spinning solution, a spinnerette associatedwith said precipitating apparatus, with the extrusion holes in saidspinnerette being so arranged so as to deliver at least two distinctbundles of filaments of different denier, a plurality of funnels, eachof which is disposed to receive one of said bundles of filaments, atleast one of said funnels having a length greater than said otherfunnels, the longer of said funnels having a reduced nipple opening inits free end, means disposed beneath said longer funnels to temporarilyreceive the laments issuing therefrom in piled relation, means forguiding the filament bundles from said tunnels to a thread uniting meanswhereby the natural adhesiveness of said filaments causes the formationof a composite filament bundle, collecting means for said compositefilament bundle, and means for treating said composite fialment bundlewith an acid regenerating bath while being collected on said collectionmeans.

9. Apparatus as claimed in claim 8 wherein said means for receiving thefilaments in piled relation comprises a at surface.

10. Apparatus as claimed in claim 8 wherein said means for receiving thefilaments in piled relation comprises a movable dished receptacle.

11. Apparatus as claimed in claim 8 wherein the increased length of thelonger of said funnels is obtained by means of an adjustable anddetachable nipple secured to the free end thereof.

References Cited in the file of this patent UNITED STATES PATENTS

8. APPARATUS FOR SPINNING NOVEL FILAMENTS OF ARTIFICIAL ORIGIN HAVINGIMPROVED STRENGTH AND SOFTNESS COMPRISING MEANS FOR DELIVERING ACELLULOSIC SPINNING SOLUTION AT A PREDETERMINED PRESSURE, PRECIPITATINGAPPARATUS TO RECEIVED SAID SPINNING SOLUTION, A SPINNERETTE ASSOCIATEDWITH SAID PRECIPITATING APPARATUS, WITH THE EXTRUSION HOLES IN SAIDSPINNERETTE BEING SO ARRANGED SO AS TO DELIVER AT LEAST TWO DISTINCTBUNDLES OF FILAMENTS OF DIFFERENT DENIER, A PLURALITY OF FUNNELS, EACHOF WHICH IS DISPOSED TO RECEIVE ONE OF SAID BUNDLES OF FILAMENTS, ATLEAST ONE OF SAID FUNNELS HAVING A LENGTH GREATER THAN SAID OTHERFUNNELS, THE LONGER OF SAID FUNNELS HAVING A REDUCED NIPPLE OPENING INITS FREE END, MEANS DISPOSED BENEATH SAID LONGER FUNNELS TO TEMPORARILYRECEIVE THE FILAMENTS ISSUING THEREFROM IN PILED RELATION, MEANS FORGUIDING THE FILAMENT BUNDLES FROM SAID FUNNELS TO A THREAD UNITING MEANSWHEREBY THE NATURAL ADHESIVENESS OF SAID FILAMENTS CAUSES THE FORMATIONOF A COMPOSITE FILAMENTS BUNDLE, COLLECTING MEANS FOR SAID COMPOSITEFILAMENT BUNDLE, AND MEANS FOR TREATING SAID COMPOSITE FIALMENT BUNDLEWITH AN ACID REGENERATING BATH WHILE BEING COLLECTED ON SAID COLLECTIONMEANS.